Parcel sorter system and method

ABSTRACT

A system for managing shipment containers includes a storage and retrieval system and at least one processor. The storage-and-retrieval system includes a framework defining a plurality of adjacent stacks capable of receiving a plurality of stackable containers, each stackable container suitable for containing a shipment container; and plural robotic pickers/load handlers configured to retrieve selected stackable containers from the framework for sortation and/or dispatch. The at least one processor is configured to: receive or access destination address information for each of the plurality of shipment containers entering the system; select a subset of the plurality of shipment containers for dispatch based on shipment container information, and generate signals for instructing at least one robotic picker to retrieve the selected shipment containers for dispatch.

FIELD OF THE INVENTION

The disclosure herein relates to systems and methods for orderfulfillment. In particular, the disclosure provides systems and methodsfor managing shipment items in an order fulfillment process.

This application claims priority from UK application number GB1411254.4the content of which is hereby incorporated by reference.

BACKGROUND OF THE INVENTION

In the delivery industry, countless packages are collected from largenumbers of locations spread across large geographical areas, and areprocessed before being shipped to their destinations.

Various forms of fully- and semi-automated sorting systems are known.They, and the various components they comprise, may take many forms. Insome systems, packages travel along a conveyor which passes by a numberof unloading stations each corresponding to a geographic destination.When a package on the conveyor passes the appropriate station, it isdiverted by mechanisms such as stationary or pivoting barriers, tilttrays, or live roller beds. In some examples, these conveyor-typesorters can have a limited number of stations, and can require multiplepasses to compete the sorting process.

There is need for improvement in the efficiency of systems and processesfor sorting and/or managing shipment items.

SUMMARY OF THE INVENTION

In various aspects, the disclosure herein provides methods, systems, andcorresponding machine-executable coded instruction sets for sortingand/or managing shipment items.

In one aspect, there is provided a system for managing shipmentcontainers. The system includes: a storage-and-retrieval systemcomprising: a framework defining a plurality of adjacent stacks, eachstack capable of receiving a plurality of stackable containers, eachstackable container suitable for containing a shipment container; tracksarranged above or below the framework to provide access to stackablecontainers received in the framework; and a plurality of roboticpickers/load handlers configured to move along a direction of the tracksand to retrieve selected stackable containers from the framework forsortation and/or dispatch. The system also includes at least oneprocessor configured to: receive or access destination addressinformation for each of the plurality of shipment containers enteringthe system; select a subset of the plurality of shipment containers fordispatch based on shipment container and generate signals forinstructing at least one of the plurality of robotic pickers to retrievethe selected shipment containers for dispatch. The selection of theshipment containers is based on at least one of: a priority of theselected shipment containers; a capacity of a shipping vehicle on whichthe selected shipment containers are to be dispatched; and thedestination addresses of the plurality of selected shipment containers.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is illustrated in the figures of the accompanyingdrawings, which are meant to be exemplary and not limiting, and in whichlike references are intended to refer to like or corresponding parts.

FIGS. 1, 2, 5, 7, 9, and 11-13 are schematic block diagram illustratingexample processes and systems to which aspects of the invention can beapplied.

FIGS. 3-4 are example views of aspects of a sortation system suitablefor use in implementing aspects of the invention.

FIG. 6, 8, 10 are flowcharts showing example methods in accordance withaspects of the invention.

DESCRIPTION OF EMBODIMENTS

Preferred embodiments of methods, systems, and apparatus suitable foruse in implementing the invention are described through reference to thedrawings.

The sortation of shipment containers, such as boxes, envelopes, parcels,bags, crates, trays, wrapped goods, and the like, is often part of alarger shipping network. For example, FIG. 1 shows a shipping network 10to which aspects of the present disclosure may be applied. In thisexample of a traditional tiered shipping network, a shipment containeris picked up from its source by a person, van or other vehicle and istransported to a distribution system 11 where the shipment container istransferred to a truck or other vehicle to be transported to an originregional sorting centre 15. At the regional sorting centre 15, theshipment container is sorted by an automated sorting system 20.

If the shipment container has a destination within the same region, theshipment container is transported back to a destination distributionsystem 11. If the shipment container has a destination in a differentregion, the shipment container is transported via plane, train, truck,or other vehicle to a destination regional sorting centre 15.

At the destination regional sorting centre 15, the shipment container issorted again by an automated sorting system 20 so that it can betransported to the proper destination distribution system 11.

FIG. 2 shows another example shipping network where a single centralregional sorting centre 15 for all distribution systems 11 in thenetwork.

As illustrated for example in the shipping networks shown in FIG. 1 andFIG. 2, a single regional sorting centre 15 may service any number ofdistribution systems 11. In some examples, a regional sorting centre 15may be associated with hundreds or even thousands of distributionsystems 11. Similarly, while the example shipping network in FIG. 1shows two regional sorting centres 15, any number of regional sortingcentres is possible. These sorting centres may be associated withgeographic areas and/or distribution systems 11 based on geographiclocation, population distributions, volume of shipment containers, orany other factors.

In other examples, a shipping network may have three or more levels ofdistribution. For example, the regional sorting centres 15 in FIG. 1could feed into a larger sorting centre which may receive shipmentcontainers from regional sorting centres 15 or distribution systems 11for sorting before being transported to the appropriate regional sortingcentre 15.

In any of the above examples or otherwise, when a shipping containerarrives at the destination distribution system 11 (e.g. from an originregional sorting centre or another destination regional sorting centre),the shipment container is sorted into vans or other vehicles fordispatch to the final destination. In some examples, this may involvemanual sortation, or an automated sorting system 20 a. Whether automatedor manual, the sorted shipment containers for one or more shippingvehicles may be manually sequenced. In one example, shipment containersare manually placed non-sequentially in an arrangement of pigeon holesbased on sequencing criteria and then are removed in a defined sequence.

As illustrated by the above example, traditional sortation of shipmentcontainers may involve multiple steps, some of which may be manuallyintensive, and may involve multi-tiered systems and transportationbetween them. Such systems using conventional conveyor-type sorters mayrequire multiple sorting passes at a single location, sorting passes atmultiple locations, and/or manual sequencing at one or more locations.

Shipping networks having parcel storage/handling hubs are generally verydynamic in that parcels are constantly arriving and leaving based on,for example, delivery chains and the just-in-time nature of operation ofshipping businesses. In each hub, significant volumes of shipmentcontainers may arrive via any number of media (e.g. air, land, rail,water, etc.), and may be tracked, stored and redirected for furthertransport. In some industries or applications, this process may requirequick turnarounds and throughputs of storage, retrieval and dispatch ofthe shipment containers. When loading vehicles, there may be limitedprocessing points for dispatch of shipment containers from a warehouseto a point of transportation (e.g. shipping docks for transfer to trucksor vans) or handling points for delivery to airplanes, trains, ships orother large vehicles. Due to the volume and limited number of processingpoints, there may be relatively small windows of time to locate,retrieve and deliver selected shipment containers to the requiredvehicles or locations.

In some instances, storage/handling hubs may be located on expensivereal estate (e.g. near docks, airports, etc.), and therefore, there maybe an interest in utilizing finite space as efficiently as possible.

With reference to FIG. 3, an example system for managing shipmentcontainers may include a fully- and/or semi-automatic storage andretrieval system 310. One manner of providing access to shipmentcontainers stored for fully- and/or semi-automatic retrieval, forexample, comprises placement of shipment containers, which may be of anydesired type(s), in bins or other containers (hereinafter referred togenerically as containers), and stacking and/or otherwise disposing thecontainers vertically in layers, and optionally in multiple columnsand/or rows, such that individual containers may be accessible by whollyor partially-automated container retrieval systems. Such systems can forexample comprise various combinations of containers; container stacksupport mechanisms, which may include mechanical devices such as framesand/or free-standing, stackable, and/or otherwise specializedcontainer(s); and automated or semi-automated (i.e., “robotic”)retrieval devices, such as load handlers which may for example operateon grids or other forms of rails, using wheels, and/or on other forms ofmechanical traveling devices. In some examples, rather than being placedwithin containers manipulated by the storage-and-retrieval system, theshipment containers may configured such that they can be stored in thestorage-and-retrieval system without being placed within the containersor bins.

For example, as shown in FIG. 3, storage and retrieval systems may beprovided in forms comprising a framework of rows and columns of stackedcontainers, in combination with overhead rail-operated load handlers 320or other robots configured to access the containers for both storage andremoval, from above. In another example, the storage and retrievalsystem may include load handlers as part of a gantry system for storingand retrieving the containers.

In some examples, the containers for storing and retrieving may have auniform or substantially uniform size. In some embodiments, the systemmay be configured to handle containers of different sizes. For example,different containers may have different heights but similarly-sizedfootprints (i.e. lengths and widths).

In another example, the system may configured to handle containershaving different sized footprints and/or heights, but may be confined tostoring different containers in specific stack locations associated withthose dimensions. These example systems may utilize different loadhandlers for storing and retrieving the differently-sized containers.

In some embodiments, the storage and retrieval system 310 may include aplurality of ports or other access points through which containers canbe inducted or dispatched from the storage and retrieval system. Theseports may include any one or combination of ramps, conveyors, pulleys,lifting devices, or any other mechanism(s) suitable for movingcontainer(s) to/from the storage-and-retrieval system, or for holdingthe container(s) temporarily until they can be moved to/from thestorage-and-retrieval system. In some examples, from the ports, thesystem may move the containers for positioning in/on a vehicle, palletand/or roll cage. In some examples, the ports may be configured suchthat the load handlers transport the container(s) retrieved from thestorage and retrieval system 310 directed into/onto a vehicle, palletand/or roll cage.

The storage and retrieval system 310 can be configured such that theload handlers can move, manipulate and/or transport container(s) to andfrom the ports and/or between different locations within the storage andretrieval system. In some examples, the load handlers may be configuredto handle different sized containers. For example, in systems havingcontainers of different heights, the systems may include different loadhandlers for each differently sized container (e.g. a taller containermay require a taller load handler) (See, for example, FIG. 4). In otherexamples, the load handlers may be configured to handle any sizedcontainer in the system.

The load handlers may be configured to receive instructions from or tobe controlled by one or more processor(s). The processor(s) and loadhandlers may be configured to communicate over a communication networkcapable of handling a communications with a large number (e.g.thousands) of load handlers. In some examples, the communication networkmay be a wireless network such as Wi-Fi, OFDMA (OrthogonalFrequency-Division Multiple Access), or any other network configurationor protocol.

The storage and retrieval system 310 may include a large number of portsor other access points. For example, the system may include a port forevery row and/or column, or a port for every other row and/or column. Inanother example, the system may include a port every X feet (e.g. every4 feet). The number of ports maybe relative to the size of the storageand retrieval system 310 and/or the number of load handlers 320. Forexample, in a 1000×600 ft or 600,000 ft² sorter, the system maygenerally have 200-300 ports but could reach up to 500 ports.

In some examples, having a large number of ports may improve thethroughput and/or efficiency when inducting or dispatching shipmentcontainer(s) to or from the storage and retrieval system 310.

In example embodiments, the shipment containers can be placed withincontainers for storage in the storage and retrieval system 310. Theseshipment containers may be in any form, shape, weight and/or sizesuitable for placement within the storage and retrieval systemcontainers. For example, shipment containers can include, but are notlimited to, boxes, envelopes, parcels, bags, crates, trays, wrappedgoods, or any other container suitable for being shipped.

As described herein, the storage and retrieval system 310 may, in someexamples, be configured to provide containers for dispatch in a sortedand/or sequenced manner.

FIG. 5 shows an example shipping network 500 which includes or to whichaspects of the present disclosure may be applied. FIG. 6 shows anexample method 600 for managing shipment containers and will bedescribed by way of example with reference to FIG. 5. The shippingnetworks described herein may include one or more servers, controlsystems, and communication networks including one or more processorsconfigured to track and manage shipment container information, and toschedule, sort and/or sequence shipment containers for dispatch inaccordance with any of the example methods described herein.

In an example scenario, an incoming shipment container arrives at theexample shipping network 500 at a distribution system 11 via a van orother vehicle. This van or other vehicle may have picked up one or moreshipment containers from a customer location, a postal outlet, amailbox, or any other depot or similar location. At the distributionsystem 11, the shipment container may be transferred to a truck or othervehicle to a sortation system 15, 515 including a storage and retrievalsystem 310. Depending on distance or other considerations, in someexamples, shipment containers may arrive directly at the sortationsystem 15, 515 without first arriving at the distribution system 11.

Upon its arrival at the sortation system 15, 515, the shipment containermay optionally be weighed and/or measured to verify size and or weightinformation associated with the shipment container in a system databaseor other electronic storage. Information associated with the shipmentcontainer such as the size and weight information as well as destinationinformation may be entered into the system at any point before theshipment container is retrieved for dispatch. For example, informationassociated with the shipment container may be received from a customerorder, from an entry at a post office or other depot, or via a datainput at the distribution base or sortation system 15, 515.

The shipment container can, in some examples, be placed in a storage andretrieval container for subsequent storage and/or management within thestorage and retrieval system. Generally, for greater ease in tracking,each shipment container may be stored within a separate storage andretrieval container. However, in some example embodiments, two or moreshipment containers may be stored within the same storage and retrievalcontainer. This may be applied in scenarios for example when multipleshipment containers, which fit in a single storage and retrievalcontainer, are destined for the same final or intermediate destination.

The shipment container, within a storage and retrieval system containeror otherwise, can be inducted or otherwise stored in the storage andretrieval system 310 via one or more ports. Induction or storage may, insome examples, involve scanning a barcode, RFID or other identifier onthe shipment container and/or placing the shipment container within astorage-and-retrieval system container. Induction or storage may alsoinvolve associating the shipment container identifier with an identifierand/or location associated with the storage-and-retrieval systemcontainer in which the shipment container is placed.

The sortation system 15, 515 can be configured to receive instructionsto prepare one or more selected shipment containers for dispatch. Uponreceiving these instructions, one or more load handlers can beconfigured to receive instructions to retrieve containers containing theselected shipment containers. The selected shipment containers can bedispatched from the storage-and-retrieval system 310 via the loadhandler(s) and/or port(s) in an order such that the shipment containersare grouped into groupings associated with the last leg vehicle whichwill be used to dispatch the selected containers to their finaldestinations. In some examples, the shipment containers can be sequencedbased on an order for loading the last leg vehicle, and/or a deliveryorder/route to be potentially followed by the last leg vehicle.

In some examples, each grouping associated with a different last legvehicle may be stored separately. For example, a grouping for a last legdelivery van may be stored in a roll cage, on a pallet, or in a largebag or other larger container. In other examples, the grouping(s) may bemaintained simply by storing and/or loading the shipment packages into avehicle in a known sequence and/or with physical (e.g. tags, stickers),or logical (e.g. shipment container identifiers) mechanisms forseparating the groupings. In some examples, the groupings may be kepttogether by storing each grouping in a separate section/division of avehicle.

Upon their selection and retrieval from the storage and retrievalsystem, the grouped shipment containers having destinations associatedwith the same distribution system 11 can be transported to thedistribution system 11 via a truck or other vehicle.

Since the shipment containers are already grouped and sequenced, at thedistribution system, the shipment container groupings can be loaded ontolast leg vehicles with little or no sorting/processing/handling at thedistribution system 11. In some examples, the distribution system 11 mayperform little or no sortation or sequencing. These processes andsystems may, in some scenarios, provide simpler, faster, lower-cost,and/or more efficient shipment container management at the distributionsystem 11 and/or in the shipping network as a whole.

When the shipment containers are grouped onto pallets, roll cages orother containers, the entire pallet(s), roll cage(s) or othercontainer(s) can be transferred from the vehicle arriving from thesortation system 15, 515 to the last leg vehicle for dispatch. This cantake place at a pallet handling station or other location which may, insome examples, include temporary storage for the groupings until a lastleg or other vehicle is available.

In some example embodiments, the placement of storage and retrievalcontainers within the storage and retrieval system during induction orduring any rearrangement or shuffling of containers can be controlled byone or more processors at the sortation system 15, 515 or elsewhere inthe shipping network. These or other processor(s) can be configured togenerate signals for controlling or instructing the load handlers.

In some scenarios, the processor(s) may be configured to generatesignals for stacking a container in a stack in the storage and retrievalsystem, the stack corresponding to a vehicle load. In some examples, oneor more stacks may be associated with a single vehicle load. In someexamples, containers may be stored in a stack in a reverse order to theorder in which they need to be grouped on a pallet, roll cage orvehicle. Once all the shipment containers for a given vehicle are in thesortation system, the load handlers can be instructed/controlled totransport the containers to a load station where the shipment containerscan be removed from the storage and retrieval containers and placed ontopallets, roll cages, or into a vehicle. The removal and placement of theshipment containers may be done manually or with (semi-)automatedrobot(s) or other equipment. In examples where every stack correspondsto a different destination or vehicle, and each grid location requiresapproximately 5 ft², a 1000×600 ft grid could have 120,000 destinations.Such an example system can be used to sort/sequence for a very largedelivery fleet.

As illustrated in the above example, sorting/sequencing of thecontainers can be generally performed during the induction of a newshipment container into the system, and potential rearrangement ofproximate containers. However, in another example, thesorting/sequencing of the containers may be performed during theretrieval of the containers.

For example, during induction, the containers may be stored atpseudo-random storage locations within the system, with the processor(s)monitoring or otherwise keeping track of the container at each storagelocation. Once the containers for filing or near-filling a vehicle load(or upon another trigger), the processor(s) can be configured toinstruction/control the load handler(s) to assemble the containers forthe vehicle load. Even though the selected containers may be dispersedat different locations in the system, these instructions can begenerated in an order or manner such that the containers arrive at theload station in the desired grouping and/or sequence.

In other examples, the sorting/sequencing or otherwise arrangement ofthe containers in the system may be during induction, during retrieval,or during an interim period. For example, the processor(s) may beconfigured to instruct the load handlers to sort/sequence containers ina stack associated with a vehicle during induction when load handlersare available, and to store containers pseudorandomly when load handlersare not readily available. This may depend, for example on load handlercongestion or backlogs in induction, retrieval, etc. During interimperiods, the processor(s) may be configured to instruct available loadhandlers to move or otherwise rearrange any (pseudonrandomly-stored orotherwise) container not in a stack associated with a desired vehicle toa stack (and, when possible/desired, in a sequence) associated with thedesired vehicle.

A conventional conveyor/redirection sorter as described in thebackground may be able to sort 20,000 to 50,000 parcels per hour. Incontrast, a grid sorter as described herein having 10,000 load handlers,which could each perform approximately 50 moves per hour, couldpotentially sort 250,000 to 500,000 parcels per hour.

In some examples, the example embodiments described in FIGS. 5 and 6 maybe well-suited for relatively dense shipment networks such as a shippingnetwork for the Netherlands.

FIG. 7 shows an example shipping network 700 which includes or to whichaspects of the present disclosure may be applied. FIG. 8 shows anexample method 800 for managing shipment containers and will bedescribed by way of example with reference to FIG. 7.

In the example shipping network 700, sortation system(s) 515, asdescribed for example with reference to FIGS. 5 and 6 or otherwise, canbe located at one or more distribution system(s) 11. Upon arrival at thedistribution system(s), incoming shipment containers can be inducted atthis initial distribution system 11. The shipment containers destinedfor a different distribution system can be retrieved and sorted/groupedin a similar manner to the other examples described herein. However, atthis stage, sequencing of the shipment containers may not be performed.The retrieved and grouped shipment containers (in pallets, roll cages orotherwise) can be transferred by truck or other vehicle to a regionalcentre 15.

Since the shipment containers are already grouped when they arrive atthe regional centre, the shipment container groupings can be loaded ontovehicles on which they can be transported to a destination distributionsystem 11, or to a second destination regional centre 15 andsubsequently to a destination distribution system 11 associated with thesecond destination regional centre. At the regional level, no individualshipment container sorting may be necessary, but rather thegroupings/pallets/roll cages may be handled and transferred to a vehicledestined for the proper destination distribution system.

When the shipment containers arrive at their destination distributionsystem 11, 515, if not already sequenced, the shipment containers may beinducted into the destination distribution system 11, 515 for storage,sorting and/or sequencing (potentially with other shipment containersfrom a different initial distribution system) before being dispatched toa last leg vehicle.

In some examples, the example embodiments described in FIGS. 7 and 8 maybe well-suited for geographically larger shipping networks such as onefor the United States or North America.

FIG. 9 shows an example shipping network 900 which includes or to whichaspects of the present disclosure may be applied. FIG. 10 shows anexample method 1000 for managing shipment containers and will bedescribed by way of example with reference to FIG. 9.

In the example shipping network 900, sortation system(s) 515, asdescribed for example with reference to FIGS. 5 and 6 or otherwise, canbe located at one or more distribution system(s) 11, and one or moreregional centre(s) 15.

Incoming shipment containers can be inducted into a sortation system 515at a local/distribution system 11 or can bypass this system and beinducted into a sortation system 515 at the regional centre 15. Thisdecision may be performed as a pre-sort at the local/distributioncentre, or may be performed as the incoming van or other vehicle ispicking up the shipment containers at their source.

Both the local/distribution 11 sortation system and the regional centre15 sortation system can be configured to group and sequence shipmentcontainers into vehicle groupings as described in other examples herein.

One or more processor(s) in the network 900 may be configured todetermine where a shipment container should be stored and/or sorted in amanner that seeks to optimize the utilization of vehicles and sortersacross the network.

In some examples, the example embodiments described in FIGS. 9 and 10may be well-suited for relatively dense shipping networks as may existin Germany, France or the U.K.

FIGS. 11 and 12 show example shipping networks wherein conventionalconveyor-redirection based sorters are used in conjunction with any ofthe example grid sorters described herein. These shipping networks maybe utilized during a transition from a network with only conventionalconveyor-redirection based sorters to the grid-based sorter networksdescribed herein.

FIG. 13 shows an example shipping network wherein conveyor-redirectionbased sorters can be retained at one or more sortation centres alongwith a grid-based sorter system such as any of those described herein orotherwise. In some such example embodiments, the conveyor-redirectionbased sorter(s) can be used to sort in-coming shipment containers to thevarious sortation centres, while the grid-based sorter(s) can be used tosort and sequence out-going shipment containers for distributionvehicles in its own region. In some examples, at the local distributioncentres, the handling of shipment containers may be reduced to movingready-packed pallets or roll cages from the vehicles coming from theregional sortation centres to distribution or last leg vehicles(cross-docking).

While in the examples above, incoming shipment containers are describedas arriving from vehicles, in some examples, incoming shipmentcontainers may arrive via conveyor or other transport mechanisms from apicking station or other system as part of an order fulfillment process.Once a shipment container for an order has been picked, the shipmentcontainer may be directed to a sortation system 515 at a distribution orregional centre in accordance with any of the examples described hereinor otherwise. In some examples, the grid-based sortation system maystore/manage both inventory for picking as well as shipment containersfor storing/sorting/sequencing.

As described broadly in the above examples, and illustrated by way ofexample in FIGS. 6, 8 and 10, one or more processor(s) may be configuredto collect and manage information associated with a shipment packagesuch as size, weight, destination address, priority, current location,storage location within a sortation system 515, etc. These processor(s)may be distributed and/or located at any location or system in theshipping network.

With at least some of this information, the processor(s) may beconfigured to track the movement, locations and destinations of shipmentcontainers. The processor(s) can be configured to store, sort, groupand/or sequence the shipment containers based on any number of factorsincluding but not limited to the destination of the shipping containers,the priority of the shipment containers, and the capacity of a shippingvehicle on which selected shipment containers are to be dispatched.

In some examples, higher priority shipment containers may be scheduledfor storage to and/or retrieval from the storage and retrieval system310 before lower priority shipment containers. When a vehicle isavailable, in some examples, one or more priority shipment containerscan be selected for grouping, sequencing and/or loading into the vehiclebefore lower priority containers. Unlike conventional systems, theability of a grid-based sortation system 515 to hold back or reschedulelower priority parcels may reduce vehicle movement and/or may reducedelivery times for priority containers. In some examples, lower priorityshipment containers maybe moved opportunistically, for example to fill avehicle partially-filled with higher priority containers. This can, insome instances, be particularly beneficial for long hauls or viaexpensive transport.

In some examples, the processor(s) may be configured to select, groupand/or sequence shipment containers such that as much of the capacity ofa vehicle is filled as would be efficient. In some examples, theprocessor(s) may be configured to sequence shipment containers in anorder which makes it easier to load a vehicle (e.g. an order whichallows larger shipment containers to be loaded first). In otherexamples, the processor(s) may be configured to sequence shipmentcontainers in an order similar to the order in which the containers areto be delivered by the last leg vehicle.

In some examples, the processor(s) may be configured to select, groupand/or sequence shipment containers such that the total delivery timefor the last leg vehicle based on the destinations of the selectedcontainers and the travel times between them maximizes or utilizes themost time of a driver's shift.

As will be further understood by those skilled in the relevant arts,significant advantage may be realized through the full or partialautomation of any of the processes described above, or portions thereof.Such automation may be implemented by, for example, providing automatedinduction into the grid sorter by means of industrial robots, conveyorsand scanners as well as automated exit from the grid sorter by means ofindustrial robots, or other placement equipment.

Such automation may be provided in any suitable manner, including forexample the use of automatic data processors executingsuitably-configured, coded, machine-readable instructions using a widevariety of devices, some of which are known and others of which willdoubtless be developed hereafter. Processor(s) suitable for use in suchimplementations can comprise any one or more data processor(s),computer(s), and/or other system(s) or device(s), and necessary ordesirable input/output, communications, control, operating system, andother devices, including software, that are suitable for accomplishingthe purposes described herein. For example, a general-purpose dataprocessor provided on one or more circuit boards will suffice.

In the embodiments described above, it will be appreciated that thetracks and the robotic pickers/load handlers may be of any suitable sizeand form capable of performing the invention as described. However, itwill be appreciated that the tracks may comprise two substantiallyperpendicular sets of rails, together forming tracks disposed above thestacks of stackable containers. Furthermore, the robotic pickers/loadhandlers may comprise a body mounted on wheels, the first set of wheelsbeing arranged to engage with at least two rails of the first set ofrails, the second set of wheels being arranged to engage with at leasttwo rails of the second set of rails, the first set of wheels beingindependently moveable and driveable with respect to the second set ofwheels such that when in motion only one set of wheels is engaged withthe grid at any one time thereby enabling movement of the load handlingdevice along the rails to any point on the grid by driving only the setof wheels engaged with the rails. Such a track system and roboticpicker/load handling device is described in UK Patent Publication NoGB2520104A1, the content of which is hereby incorporated by reference.

In the above description it will be appreciated that a sortation systemis a system in which everything entering the system has a predetermineddestination, whereas in a storage and retrieval system items enteringthe system may be allocated a destination whilst being stored in thesystem. Whilst the above description generally relates to a storagesystem, it will be appreciated that it may also be relevant to a storageand retrieval system.

While the disclosure has been provided and illustrated in connectionwith specific, presently-preferred embodiments, many variations andmodifications may be made without departing from the spirit and scope ofthe invention(s) disclosed herein. The disclosure and invention(s) aretherefore not to be limited to the exact components or details ofmethodology or construction set forth above. Except to the extentnecessary or inherent in the processes themselves, no particular orderto steps or stages of methods or processes described in this disclosure,including the Figures, is intended or implied. In many cases the orderof process steps may be varied without changing the purpose, effect, orimport of the methods described. The scope of the invention is to bedefined solely by the appended claims, giving due consideration to thedoctrine of equivalents and related doctrines.

1. A system for managing shipment containers, the system comprising: astorage-and-retrieval system having: a framework defining a plurality ofadjacent stacks, each stack being configured for receiving a pluralityof stackable containers, each stackable container being suitable forcontaining a shipment container; tracks arranged above or below theframework to provide access to stackable containers received in theframework; and a plurality of robotic pickers/load handlers configuredto move along a direction of the tracks and to retrieve selectedstackable containers from the framework for sortation and/or dispatch;and at least one processor configured to: receive or access destinationaddress information for each of the plurality of shipment containersentering the system; select a subset of the plurality of shipmentcontainers for dispatch based on shipment container; and generatesignals for instructing at least one of the plurality of robotic pickersto retrieve the selected shipment containers for dispatch, the selectionof the shipment containers being based on at least one of: a priority ofthe selected shipment containers; a capacity of a shipping vehicle onwhich the selected shipment containers are to be dispatched; and thedestination addresses of the plurality of selected shipment containers;the system including selection means for retrieving a selected shipmentbased on a final destination of the selected shipment, wherein saidselected shipment will be retrieved at a given position in a retrievalprocess based on a sequence required for delivery of the selectedshipment.
 2. The system of claim 1, wherein the plurality of roboticpickers are configured to transport the retrieved stackable containersfor dispatch via at least one of a plurality of transfer points at thestorage-and-retrieval system.
 3. The system of claim 1, wherein theplurality of robotic pickers or a second plurality of robotic pickersare configured for inducting shipment containers into thestorage-and-retrieval system via at least one of a plurality of transferpoints at the storage-and-retrieval system.
 4. The system of claim 1,wherein the selection of the shipment containers is based on at leastone of: a weight and at least one dimension of at least one of theshipment containers.
 5. The system of claim 1, wherein the at least oneprocessor is configured to select shipment containers for dispatch inthe shipping vehicle to substantially fill a delivery period associatedwith the shipping vehicle based on the destination address informationof the shipping containers.
 6. The system of claim 1, wherein the atleast one processor is configured to select shipment containers fordispatch by not selecting a lower priority shipment container when ahigher priority shipment container is available.
 7. The system of claim1, wherein the at least one processor is configured to select at leastone lower priority shipment container along with higher priorityshipment containers when the capacity of the shipping vehicle canaccommodate the at least one lower priority shipment container.
 8. Thesystem of claim 1, wherein the at least one processor is configured togenerate signals for instructing at least two of the plurality ofrobotic pickers to concurrently retrieve selected shipment containersfor dispatch via a same shipping vehicle.
 9. The system of claim 1,wherein the at least one processor is configured to generate signals forinstructing at least two of the plurality of robotic pickers toconcurrently retrieve selected shipment containers for dispatch viadifferent shipping vehicles.
 10. The system of claim 1, wherein the atleast one processor is configured to select shipment containers fordispatch in a specific sequence.
 11. The system of claim 10, wherein thesequence is selected to decrease unfilled capacity of the shippingvehicle, or to ease loading or unloading of the selected shipmentcontainers into or out of the shipping vehicle.
 12. The system of claim10, wherein the sequence is selected based at least in part on asequence in which the shipment containers will be delivered.
 13. Thesystem of claim 1, wherein no more than one shipment container is storedin a single stackable container.
 14. The system of claim 1, wherein theat least one processor is configured to select shipment containers fordispatch to a second system for managing shipment containers.
 15. Thesystem of claim 14, wherein the at least one processor is configured toselect the shipment containers for dispatch to the second system in asequence or a grouping such that the shipment containers can bedispatched from the second system for delivery with reduced or noadditional sorting at the second system.
 16. The system of claim 14,wherein the system is a regional system configured for deliveringshipment containers having destination addresses within an associatedgeographic region and for shipping shipment containers havingdestination addresses outside the associated geographic region to thesecond system.
 17. The system of claim 16, wherein the second system isanother regional system.
 18. The system of claim 16, wherein the secondsystem is a central system configured for shipping shipment containersto the regional system and at least one other regional system.
 19. Thesystem of claim 14, wherein the system is a central system and thesecond system is a regional system.
 20. The system of claim 1, whereinthe tracks comprise: two substantially perpendicular sets of railsforming a grid above the stacks of stackable containers.
 21. The systemof claim 20, wherein the robotic pickers/load handlers comprise: a bodymounted on wheels, a first set of the wheels being arranged to engagewith at least two rails of a first set of the rails, the second set ofthe wheels being arranged to engage with at least two rails of a secondset of the rails, the first set of wheels being independently moveableand driveable with respect to the second set of wheels such that when inmotion only one set of wheels is engaged with the grid at any one timethereby enabling movement of the robotic pickers/load handling devicesalong the rails to any point on the grid by driving only a set of wheelsengaged with the rails.
 22. A method of sorting items in a system formanaging shipment containers, the system having: a storage-and-retrievalsystem having: a framework defining a plurality of adjacent stacks, eachstack being configured for receiving a plurality of stackablecontainers, each stackable container being suitable for containing ashipment container; tracks arranged above or below the framework toprovide access to stackable containers received in the framework; and aplurality of robotic pickers/load handlers configured to move along adirection of the tracks and to retrieve selected stackable containersfrom the framework for sortation and/or dispatch; and at least oneprocessor, wherein the method will: receive or access destinationaddress information for each of the plurality of shipment containersentering the system; select a subset of the plurality of shipmentcontainers for dispatch based on shipment container; and generatesignals for instructing at least one of the plurality of robotic pickersto retrieve the selected shipment containers for dispatch, the selectionof the shipment containers being based on at least one of: a priority ofthe selected shipment containers; a capacity of a shipping vehicle onwhich the selected shipment containers are to be dispatched; and thedestination addresses of the plurality of selected shipment containers;and the method will: retrieve a selected shipment based on a finaldestination of the selected shipment, wherein said selected shipmentwill be retrieved at a given position in a retrieval process based on asequence required for delivery of the selected shipment.